LSL Consulting Advances Bulk Materials Handling Design with Ansys Rocky DEM

South African consulting engineering company combines more than 45 years of bulk materials handling expertise with advanced DEM simulation to address complex engineering challenges across the mining and minerals processing industries.

LSL Consulting (Pty) Ltd is a South African consulting engineering and project management company specialising in Bulk Materials Handling (BMH) solutions for the mining, minerals processing and power generation industries.

With more than 45 years’ experience, LSL has developed extensive expertise across a diverse range of commodities and bulk materials, delivering projects throughout South Africa and internationally.

The company's specialist capabilities include:

• Custom Conveyor Systems designed for challenging terrain, constrained plant layouts and demanding process requirements.
• Transfer Chute Design focused on efficient material transfer while minimising spillage, dust generation and wear.
• Stacking and Reclaiming Solutions designed to maximise storage utilisation and reclaim efficiency.
• Rail and Truck Loading and Offloading Facilities to improve logistics and material handling performance.
• Crushing and Screening Plants, including high-capacity run-of-mine applications handling hard and abrasive ore types.
• Bulk Solids Storage and Gravity Reclaim Systems, including large-capacity silos, bunkers, surge bins and process hoppers.

Leveraging DEM for Smarter Designs

Accurate prediction of material flow behaviour is fundamental to the successful design and operation of materials handling systems. LSL incorporates the Discrete Element Method (DEM) into its engineering approach to investigate, optimise and troubleshoot bulk solids handling applications.

Using Ansys Rocky DEM, LSL engineers can simulate the movement and interaction of individual particles, providing detailed insight into material behaviour under representative operating conditions.

DEM analysis enables engineers to evaluate factors including:

• Material flow patterns
• Velocity profiles
• Impact forces
• Wear zones
• Segregation
• Material build-up and accumulation

This virtual design environment allows multiple design concepts to be evaluated before fabrication and construction. Potential operational issues can therefore be identified earlier, supporting more informed engineering decisions and reducing the risk associated with design changes later in a project.

The Importance of Material Property Calibration

The reliability of a DEM analysis depends heavily on the quality and suitability of the material properties used in the simulation.

Bulk solids are complex materials, with behaviour influenced by particle size distribution, shape, density, moisture content, surface characteristics and composition. Although many of these parameters can be measured directly, few can be used as direct inputs into a DEM model – most DEM material parameters require calibration against physical test data, typically achieved via laboratory analysis on representative material samples

This approach is essential for developing confidence in simulation results. A visually convincing DEM model is not necessarily an accurate representation of real-world material behaviour unless the underlying material properties have been appropriately characterised and calibrated.

Transfer Chute Design

Transfer chutes are critical components in bulk materials handling systems. Poorly designed chutes can contribute to spillage, excessive wear, dust generation, material degradation, equipment damage and unplanned maintenance.

By applying DEM during the design process, LSL can investigate and optimise:

• Chute geometry according to the flow characteristics of the material.
• Throughput performance under normal and upset operating conditions.
• Material trajectories and flow patterns throughout the transfer.
• Impact forces and wear intensity distribution to support liner selection and service-life considerations.
• Product degradation and material breakage during transfer.
• Loading conditions for controlled and efficient transfer onto downstream equipment.

The resulting insight allows potential performance and maintenance issues to be addressed before equipment is fabricated and commissioned.

Figure 1: DEM Analysis of Guided Flow Hood & Spoon Chute

Bulk Solids Storage and Gravity Reclaim Systems

The design of storage bins, silos, hoppers and gravity reclaim systems requires a detailed understanding of bulk solids flow behaviour.

When combined with laboratory flow-property testing, DEM can provide valuable insight into material movement and discharge behaviour within storage and reclaim systems.

LSL engineers use DEM simulation to evaluate:

• Feeder and outlet configurations for controlled and uniform material withdrawal.
• Extraction performance and discharge flow patterns.
• The potential for arching, bridging and flow obstructions.
• Mass-flow and funnel-flow behaviour.
• Material residence time and potential dead-storage zones.
• Load distribution and interactions between stored materials and reclaim equipment.

Identifying potential flow-related challenges during the design phase helps ensure reliable discharge performance from bulk storage systems

Figure 2: DEM Analysis of a Coal Truck Loading Station

Figure 3 : DEM Evaluation Confirming the Influence of Feeder Interfacing on Bin Discharge Performance

Engineering Confidence Through Simulation

The integration of DEM into LSL's engineering methodology provides an additional layer of insight across a range of bulk materials handling applications.

From transfer chutes and storage facilities to conveyors, crushing plants and train/truck loading systems, simulation enables engineers to examine material behaviour and compare design alternatives before construction.

By combining specialist knowledge of bulk materials handling with physical material testing and numerical simulation, LSL can develop practical engineering solutions informed by both real-world experience and detailed analysis.

Qfinsoft and Ansys Simulation

LSL Consulting's use of Ansys Rocky DEM is supported by Qfinsoft (Pty) Ltd, a trusted Ansys Channel Partner since 1999.

Qfinsoft provides Ansys simulation solutions, training, consulting and technical support to engineers, researchers and organisations across Sub-Saharan Africa. Its role is to help customers effectively apply simulation technology to complex engineering challenges and integrate it into their existing engineering workflows.

The collaboration between Qfinsoft and LSL Consulting demonstrates how advanced simulation technology can complement established engineering expertise. Through access to Ansys Rocky DEM and associated technical support, LSL is able to incorporate advanced particle-based simulation into its broader approach to bulk materials handling design and optimisation.

Meet Qfinsoft at Electra Mining Africa

Qfinsoft will be at Electra Mining Africa from 7–11 September 2026, and we look forward to connecting with industry professionals, engineers and visitors at the show.

Come and visit us to learn more about Ansys simulation solutions and how advanced simulation can support real-world engineering challenges.

Hall: 5 (previously Hall 6)
Stand: B14

We look forward to seeing you at Electra Mining Africa.

Contact

Qfinsoft (Pty) Ltd

Contact: Izak Forster
Email: izak@qfinsoft.co.za
Website: Qfinsoft – Engineer The Future with Simulation

LSL Consulting (Pty) Ltd

Contact: Mike Reynolds
Email: miker@lsltek.co.za
Website: LSL Consulting | Tekpro